Devices and method for examining connectors

Abstract: To judge with certainty whether the condition of attachment of each metal terminal is proper, a method and apparatus are provided in which a thinned distal end portion of a lance check pin having guide portions contacts an inner surface of a lance flexing space. The lance check pin, when inserted into the lance flexing space, is kept in a proper posture by the guide portions. Therefore, misjudgment of the terminal position is avoided. In addition, to eliminate the need for a retainer, there is provided a method and apparatus in which metal terminal-inserting jigs are inserted into a connector, so that pressing portions of the jigs are inserted into cavities through insertion holes of a connector housing. Metal terminals disposed in an improperly-inserted position are pushed by distal ends of pressing portions of the jig, and are moved to a properly-inserted position where the metal terminal is held against withdrawal by the engagement portion of a lance. The jigs are reusable, thereby reducing the number of the parts. Even if the metal terminal is disposed in an improperly-inserted position, the metal terminal need not be removed reinserted, and reinspected.

Description: BACKGROUND OF THE INVENTION This invention relates to a connector examination device and method for detecting improper attachment of a metal terminal inserted in a connector housing. Generally, a connector comprises a connector housing of a plastics material in which metal terminals, each fixedly secured to one end of a wire, are mounted, and each metal terminal is retained against withdrawal by a lance (elastic retaining pawl) formed integrally within the connector housing. When the metal terminal is inserted into the connector housing, the lance is flexed downwardly toward a flexing space until the metal terminal is inserted into a proper position, at which point the lance is elastically restored to engage a void formed along a bottom surface of the metal terminal, thereby preventing withdrawal of the metal terminal. With this type of terminal withdrawal prevention construction, a certain degree of a frictional force acts between the metal terminal and the lance when the metal terminal is inserted. The frictional force is of such a degree that the metal terminal cannot be inserted into the housing any further, which may give the impression to an operator that the terminal is reliably secured by the lance, even though it is not properly inserted into the housing. Accordingly, the operator, engaged in the inserting operation, may misunderstand that complete insertion has been achieved, and may stop the inserting operation before the lance actually engages the terminal. However, if the metal terminal is not completely inserted into the proper position where the metal terminal engages the lance in the connector housing, the metal terminal can become withdrawn from the housing during use. Therefore it is necessary to preliminarily inspect the terminal connections to correct any improperly inserted or incompletely connected terminals. Recently, various kinds of connector examination devices have been developed for detecting improper attachment of a metal terminal. The present applicant filed an application (Japanese Patent Application No. 5-281716) shown in Fig. 7. In this construction, a lance check pin 51 is provided in a projected manner in opposed relation to each lance 61 in a connector 60, and the lance check pin 51 is adapted to be inserted into a lance flexing space 63 formed in a connector housing 62. When a metal terminal 65 is completely inserted into a proper position, the lance check pin 51, inserted in the lance flexing space 63, does not strike against the lance 61, but is brought into underlying relation with the lance, as shown at an upper stage in Fig. 7. When the metal terminal 65 is in an improperly-attached condition, the lance check pin 51 strikes against the distal end of the lance 61 that is elastically deformed in the lance flexing space 63, as shown at a lower stage in Fig. 7. In this construction, when the metal terminal 65 is in an improperly-attached condition, with the lance 61 disposed in the lance flexing space 63, the lance check pin 51 strikes against the distal end of the lance 61. Accordingly, the check pin 51 cannot be positioned beneath the lance 61. As a result, improper attachment of the metal terminal 65 occurs. For molding reasons, even when the metal terminal 65 is completely inserted into the proper position, with the lance 61 substantially retracted from the lance flexing space 63 and into the terminal 65, the lance 61 still projects slightly inwardly towards an inner wall surface of the lance flexing space 63. In this connection, a distal end portion 51a of the lance check pin 51 is made smaller in thickness than the lance flexing space 63 so that the lance check pin can be brought into underlying relation to the lance 61. Therefore, a gap is formed between the distal end portion 51a of the lance check pin 51 and the bottom portion of the terminal 65. Therefore, it is possible that when the lance check pin 51 is inserted into the lance flexing space 63, the distal end portion 51a of the lance check pin 51 is inserted into the lance flexing space 63 in a bent, deformed manner, or the lance check pin 51 is inserted obliquely. In such a situation, even when the metal terminal 65 is completely inserted into the proper position, with the lance 61 fully retracted from the lance flexing space 63, the distal end portion 51a of the lance check pin 51 can strike against the slightly-projected portion of the lance 61. As a result, despite the fact that the metal terminal 65 is disposed in the proper position, the lance check pin 51 can not reach the position beneath the lance 61, and therefore it may be erroneously judged that the metal terminal 65 is in an improperly-attached condition. In addition, there have been several proposed devices to confirm and inspect the position of the terminal. For example, a retainer that engages the metal terminal (with which the lance is also engaged) is inserted into the housing when an operator believes that the terminal is in the properly-inserted position, thus providing, together with the lance, a second engagement if the terminal is inserted to a depth where the lance engages a void or hole in the terminal. The retainer is provisionally attached to the connector before the metal terminals are inserted, and in this condition, after the metal terminals are inserted, the retainer is moved into a completely-attached position to engage the metal terminals. At this time, if the metal terminal is disposed in an improperly-inserted position (short of the properly-inserted position), the retainer engages the metal terminal, and can not be moved into the completely-attached position. Thus, the retainer indicates whether the metal terminals have been inserted into the properly-inserted position. If it is judged that any metal terminal has not been inserted into the properly-inserted position, i.e., the retainer engages the metal terminal rather than a recess or the void of the metal terminal, the metal terminal is removed and tried again. In the above method in which the retainer is used to determine proper positioning of the terminals, the retainer, mounted on the connector in the completely-attached position, remains connected to the connector, and even after the inspecting of the terminal is complete, the retainers remain mounted on the connector housings. Therefore, inspection of the terminals requires a permanently mounted retainer for each terminal and therefore the cost and number of the parts required for inspecting terminals is high. Moreover, the retainer merely judges whether the metal terminal is disposed in the properly-inserted position or an improperly-inserted position, and when it is judged that the metal terminal is in the improperly-inserted position, an operator is required to remove the terminal and attempt to reinsert the terminal. After the retainer is attached again, the condition of insertion of the metal terminals is rechecked, thus requiring even more time and labor. Therefore, the overall efficiency of the metal terminal-inserting operation suffers. Document JP-Y-62 047 093 discloses a device that checks the correct insertion of a metal terminal by providing electrical slide contacts which abut a metal terminal to determine when the metal terminal is in a correct position. A stationary protruding element can be inserted into a lance flexing space to determine whether the lances are in a correct position. SUMMARY OF THE INVENTION The present invention has been made under the above circumstances, and an object of the invention is to provide a connector examination device and method capable of judging with certainty whether a metal terminal is attached in a proper or an improper condition, and can effect a highly reliable inspection. These objects may be solved by the feature combinations of independent claims 1, 4 and 13. To achieve the above objects, in an aspect of the present invention, there is provided a connector examination device according to claim 1 having lance check pins that can be inserted into lance flexing spaces for allowing elastic deformation of the lance during the insertion of a metal terminal. The lance check pin is inserted into the lance flexing space and abutted against the lance when the metal terminal assumes an improperly-attached condition. The lance check pin includes a guide portion for contacting an inner surface of the lance flexing space so as to keep the lance check pin in the proper position in the lance flexing space. A judgment device judges from the position of the lance check pin whether the lance check pin is abutted against the lance. Further, there is provided an inspection housing having a setting portion for receiving a connector to be examined; sliders mounted on the inspection housing for movement toward and away from the connector; one of the lance check pins provided on each of the sliders; and one of the judgment devices being mounted on each of the sliders. Moreover, there can be provided a connector holder for holding a connector to be examined; the inspection housing provided in opposed relation to the connector holder; a drive mechanism for reciprocally moving one or both of the connector holder and said inspection housing toward each other. The judgment means comprises an electrical contact member mounted for movement with the lance check pin to engage the metal terminal received and retained in the proper position in the connector housing against withdrawal. The electrical contact member is connected to a conduction examination circuit for a wire harness. The lance check pin may have a relief recess for preventing the guide portion from interfering with stabilizers extending from the metal terminal and straddling opposite sides of said lance. According to another aspect of the present invention, there is provided a device for inspecting a terminal inserted within a connector housing according to claim 4. The connector has a lance capable of securing the terminal in a locking position and a lance flexing space into which the lance flexibly extends as the terminal is inserted within the connector housing. The device includes a lance check pin that is inserted into the lance flexing space, and means provided on the lance check pin for guiding a tip portion of the lance check pin in a first position below a bottom portion of the lance when the lance is disposed in the locking position, even when the lance partially protrudes within the lance flexing space and the tip portion is at least one of irregularly formed and obliquely inserted. According to another aspect of the present invention there is provided a method according to claim 13 of inspecting a terminal inserted within a connector housing having a lance capable of securing the terminal in a locking position, and a lance flexing space into which the lance flexibly extends as the terminal is inserted within the connector housing. The method includes the steps of inserting a lance check pin within the lance flexing space, and guiding a tip portion of the check pin by means provided on the lance check pin in a first position below a bottom portion of the lance when the lance is disposed in the locking position, even when the lance partially protrudes within the lance flexing space and the tip portion is at least one of irregularly formed and obliquely inserted. With an examination device and method having these features, the lance engages the metal terminal, and is retracted from the lance flexing space when the metal terminal is inserted into the proper position in the connector housing. When the metal terminal is disposed in an incompletely-inserted position (short of the proper position), the lance does not engage the metal terminal, and is elastically deformed into the lance flexing space. When the metal terminal is inserted into the proper position, with the lance retracted from the lance flexing space, the lance check pin, inserted into the lance flexing space, will not abut against the lance, and is therefore positioned below the lance. The judgment device judges from the position of the lance check pin that the lance check pin is not abutted against the lance. Accordingly, a properly inserted metal terminal that is completely inserted into the housing can be detected. In contrast, when the metal terminal in the connector is disposed in an incompletely-inserted position, with the lance flexed into the lance flexing space, the lance check pin abuts against the lance, and therefore is prevented from further insertion. The judgment device judges from the position of the thus shallowly-inserted lance check pin that the lance check pin is abutted against the lance, and in accordance with this, the fact that the metal terminal is in an improperly-inserted condition is detected. In the connector examination device, the connector to be examined is received in the setting portion of the inspection housing, and each slider is moved to attempt insertion of the lance check pin into the lance flexing space in the connector to examine the position of the check pin. When the metal terminal in the connector is inserted into the proper position, with the lance retracted from the lance flexing space, the lance check pin will not abut against the lance, and therefore is inserted below the lance. The judgment device judges from the position of the lance check pin that the lance check pin is not abutted against the lance, and in accordance with this, the fact that the metal terminal is completely inserted into the proper position is detected. In contrast, when the metal terminal in the connector is disposed in an incompletely-inserted position, with the lance flexed into the lance flexing space, the lance check pin abuts against the lance, and therefore is prevented from further insertion so that the slider is prevented from moving toward the connector. The judgment device judges from the position of the shallowly-inserted lance check pin that the lance check pin is abutted against the lance, and in accordance with this, the fact that the metal terminal is in an improperly-inserted condition is detected. In the connector examination device, the connector to be examined can be set in the connector holder, and the drive mechanism moves the inspection housing and the connector holder toward each other, so that each lance check pin is inserted into the associated lance flexing space in the connector housing, thereby effecting terminal position examination. When the metal terminal in the connector is inserted into the proper position, with the lance retracted from the lance flexing space, the lance check pin will not abut against the lance, and therefore is inserted deep. The judgment device judges from the position of the thus deeply-inserted lance check pin that the lance check pin is not abutted against the lance, and in accordance with this, the fact that the metal terminal is completely inserted into the proper position is detected. In contrast, when the metal terminal in the connector is disposed in an incompletely-inserted position, with the lance flexed into the lance flexing space, the lance check pin abuts against the lance, and therefore is prevented from further insertion. The lance check pin and the slider are moved backward relative to the inspection housing. The judgment device judges from the position of the thus shallowly-inserted lance check pin that the lance check pin is abutted against the lance, and in accordance with this, the fact that the metal terminal is in an improperly-inserted condition is detected. The guide portion of the lance check pin inserted into the lance flexing space is brought into contact with the inner surface of the lance flexing space, and by doing so, the lance check pin can be inserted into the lance flexing space while being kept in the proper posture. Namely, even if the lance check pin is bent or deformed, or if the lance check pin is inserted obliquely into the lance flexing space, such deformation and oblique insertion are corrected in the lance flexing space by guiding portions formed on the check pins, so that the lance check pin can be inserted into the lance flexing space while kept in the proper posture. When the lance check pin is inserted without abutting the lance, the electrical contact member provided on the judgment device contacts the metal terminal to make an electrical connection, so that detection of the completely inserted position of the metal terminal can be detected. In contrast, when the lance check pin abuts against the lance, the electrical contact member does not contact the metal terminal, so that the electrical connection is not achieved. As a result, the improperly-inserted condition of the metal terminal is detected. Furthermore, because each electrical contact member is connected to the conduction examination circuit for a wire harness, examination for the wire harness and the examination for the position of attachment of the metal terminal can be carried out at the same time. In addition, the metal terminal can have stabilizers extending at the opposite sides of the lance, and even when the stabilizers project into the lance flexing space, the stabilizers will not interfere with the guide portion of the lance check pin. Further objects, features and advantages of the present invention will become apparent from the detailed description of preferred embodiments which follows, when considered together with the attached figures of drawings. BRIEF DESCRIPTION OF THE DRAWINGS The invention will be described in detail with reference to the following drawings, wherein: Fig. 1 is a cross-sectional view showing a first embodiment of a connector examination device of the present invention; Fig. 2 is a fragmentary, enlarged view showing a lance of a connector and a lance check pin; Fig. 3 is a cross-sectional view of the examination device, showing a condition in which the connector is set; Fig. 4 is an enlarged, cross-sectional view showing the positional relation between the lance and the lance check pin in an upper stage of Fig. 3; Fig. 5 is a cross-sectional view taken along the line V-V of Fig. 4; Fig. 6 is a cross-sectional view of a second embodiment of a connector examination device of the invention; Fig. 7 is a cross-sectional view of a connector examination device shown for comparison purposes; and Fig. 8 is an enlarged, cross-sectional view of a portion of Fig. 7. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS A first embodiment of the terminal inspecting apparatus and method aspects of the present invention will now be described with reference to Figs. 1 to 5. Reference is first made to the construction of a connector 30 to be examined by the use of an examination device 10. A connector housing 31 is molded of a resin, and has a rectangular configuration as a whole. A plurality of cavities 32 are formed in the connector housing, and are arranged in upper and lower stages. Each cavity 32 extends through the connector housing from its front to its rear end, and a metal terminal 33 is inserted into the cavity 32 from a rear side (i.e., the right side in Fig. 1). The metal terminal 33, having a wire 35 compressively connected thereto, is of a known construction, and is of the female type that mates with a male metal terminal of a mating connector (not shown). Lances 34 for retaining the respective metal terminals 33 against withdrawal are formed integrally on the connector housing 31. The lance 34 is in the form of an elastically-deformable projecting piece, and has a retaining portion 34a formed adjacent to its distal end. The retaining portion 34a projects toward the associated cavity 32. A lance flexing space 32a for allowing downward elastic deformation of the lance 34 is provided within the cavity 32, the lance flexing space being formed utilizing a mold release space. The lance flexing space 32a is open to the front end face of the connector housing 31, and has upper and lower inner surfaces parallel to each other. As will be more fully described later, when the lance 34 holds the metal terminal 33, inserted into a proper position, against withdrawal, a lower surface of the lance 34 is disposed parallel to the lower inner surface of the lance flexing space 32a. The lower surface portion of the lance 34 projects downwardly into the upper inner surface of the lance flexing space 32a (Fig. 4). When the metal terminal 33 is inserted into the cavity 32, the distal end of the metal terminal 33 abuts against the lance 34 during the insertion to urge the lance 34 downward, so that the lance 34 is elastically deformed and projected into the lance flexing space 32a. When the metal terminal 33 is inserted into an innermost portion of the cavity 32, the lance 34, elastically deformed during the insertion, is retracted upwardly from the lance flexing space 32a, that is, restored to its initial position as a result of engagement of the retaining portion 34a in an engagement hole 43a in the metal terminal 33, thereby retaining the metal terminal 33 against withdrawal. To indicate the condition of engagement of the lance 34, the metal terminal 33 in the upper stage (Fig. 3) is shown as inserted into a proper position to be completely engaged with the lance 34, while the metal terminal 33 in the lower stage is shown as disposed in an incompletely-inserted position short of the properly position, with the lance 34 elastically deformed into the lance flexing space 32a. Next, an examination device 10 for examining the above connector 30 will be described. The examination device 10 is incorporated in an inspection or checker housing 11 made of a resin. The interior of the inspection housing 11 is divided by partition walls 11a into a plurality of smaller chambers forming cavities 12 corresponding in number to the cavities 32 in the connector housing 31. The inspection housing has a hood portion 13 of a generally square or rectangular shape disposed adjacent to front ends of the cavities 12, the hood portion 13 serving as a set portion for receiving the connector housing 31 of the connector 30. A slider 14, having excellent sliding properties, is mounted within each cavity 12 for sliding movement therealong, and a lance check pin 15, formed integrally with the slider, projects into the hood portion 13 through a through hole llb formed in the partition wall lla. A relatively weak compression spring 16 mounted within the cavity 12 normally urges the slider 14 to a right side in Fig. 1. When the connector 30 is not placed in the hood portion 13, the lance check pin 15 fully projects into the hood portion 13 in such a manner that a stopper 14a, formed on the slider 14 in a projected manner, abuts against the partition wall lla. The lance check pin 15 is disposed in such a position that it can be inserted into the lance flexing space 32a in the connector housing 31 set in the hood portion 13. The lance check pin 15, when inserted into the lance flexing space 32a, moves in sliding contact with the upper and lower inner surfaces of the lance flexing space. Even when the lance 34 retains the metal terminal 33 against movement from the normal position, the lance 34 slightly projects into the lance flexing space 32a as described above. In this connection, a distal end portion 15a of the lance check pin 15 is cut at its upper surface to be reduced in thickness. Therefore, the lance check pin 15 can be inserted into a position where its distal end portion 15a underlies the lance 34. With this construction, when the metal terminal 33 is disposed in an incompletely-inserted position, with the lance 34 flexed and projection into the lance flexing space 32a, the distal end of the lance check pin 15 abuts against the distal end of the lance 34. According to the invention the lance check pin 15 is provided with means by which its distal end portion 15a can be smoothly brought into underlying relation to the lance 34. This construction will now be described. Elongate, wall-like guide portions 15b and 15b are respectively formed on and extend along lateral marginal portions (except for a widthwise central portion registrable with the lance 34) of the upper surface of the distal end portion 15a of the lance check pin 15 that can face the lower surface of the lance 34. The guide portions 15b extend parallel to the direction of the length of the lance check pin 15. Upper surfaces of the guide portions 15b are flush and continuous with the upper surface of that portion of the lance check pin 15 extending rearwardly from the distal end portion thereof, and can be brought into contact with the upper inner surfaces of the lance flexing space 32a. Distal ends of the guide portions 15b terminate a predetermined distance short of the distal end of the lance check pin 15 to provide a relief recess 15c for preventing the guide portions 15b from interfering with stabilizers 33a that project from the metal terminal 33 along the opposite sides of the lance 34. An electrical contact member 17, comprising an electrically-conductive bar, is fixedly mounted on the slider 14, for example, by press-fitting. The electrical contact member 17 extends parallel to the lance check pin 15, and a length of the contact member 17 is shorter than that of the lance check pin 15. The position of the distal end of the electrical contact portion 17 is so determined that when the connector housing 31 is set in the hood portion 13, so that the distal end portion 15a of the lance check pin 15 is brought into underlying relation to the lance 34, with the metal terminal 33 disposed in the proper position, the electrical contact member 17 contacts the distal end of the metal terminal 33. Each of the electrical contact members 17 is connected to a conduction examination circuit (not shown) via a lead wire 18. This conduction examination circuit judges whether the metal terminals 33 are properly inserted respectively into the cavities 32 in the connector 30 assembled as a wire harness. The conduction examination circuit is a known construction and incorporates a power source for conduction examination purposes, and effects an examination by judging whether electric current can flow between predetermined metal terminals of the two connectors connected respectively to the opposite ends of the wire harness. Next, the operation of this embodiment will be described. The metal terminals 33, compressively connected to respective ends of the wires 35, are inserted respectively into their associated cavities 32 in the connector housing 31, and the wires 35 are combined together into a bundle by tape or the like, thereby assembling the wire harness. In this condition, the examination for improper attachment of the metal terminals 33, as well as conduction examination, are carried out in the following manner. The wire harness to be examined is placed on a predetermined examination plate, and the connector 30 is set in the hood portion 13 of the inspection housing 11 of the connector examination device 10 (see Fig. 3). At this time, if the metal terminal 33 of the connector 30 is disposed in the proper position where it is engaged with the lance 34 of the connector housing 31 as shown in the upper stage of Fig. 3, the lance 34 is retracted upwardly, and projects slightly into the lance flexing space 32a, thereby opening the lance flexing space 32a disposed below the lance 34. Therefore, the lance check pin 15, inserted into the lance flexing space 32a upon setting of the connector 30, will not abut against the lance 34, and the distal end portion 15a of the lance check pin 15 is brought into underlying relation to the lance 34, with the two guide portions 15b and 15b disposed adjacent respectively to the opposite lateral sides of the lance 34. As a result, by the urging force of the spring 16, the slider 14 is moved forward in such a manner that the lance check pin 15 is fully projected into the hood portion 13 of the checker housing 11. As a result, the electrical contact member 17, movable with the slider 14, is also projected a maximum distance toward the connector 30, so that the distal end of the contact member is brought into contact with the distal end of the metal terminal 33, thus making an electrical connection therebetween. Therefore, it is confirmed by the conduction examination circuit that the metal terminal 33 is disposed in the proper position and that the metal terminal is mounted in the predetermined cavity 32. By contrast, if the metal terminal 33 is disposed in an incompletely-inserted position where it does not contact the lance 34, as shown in the lower stage of Fig. 3, the lance 34 is pressed down by this metal terminal 33, and projects into the lance flexing space 32a. Therefore, when the connector 30 is set in the hood portion 13 of the checker housing 11, the distal end portion 15a of the lance check pin 15 abuts against the distal end of the lance 34, and can not be brought into underlying relation with respect to the lance 34. Therefore, during the setting of the connector 30, the lance check pin 15 is prevented from advancing in the lance flexing space 32a, and the slider 14 is urged left (Fig. 3) relative to the checker housing 11 while compressing the compression spring 16. Therefore, the electrical contact member 17, integrally mounted on the slider 14, is also urged left, and can not contact the metal terminal 33, thus failing to achieve an electrical connection to the metal terminal 33. This abnormality encountered with the metal terminal 33 is detected by the conduction examination circuit. When the lance 34 is urged down into the lance flexing space 32a as described above, the distal end of the lance check pin 15 abuts against the lance 34, and therefore an insertion resistance, produced when setting the connector 30 into the hood portion 13 of the checker housing 11, is increased. Despite this, the setting should be continued. Because the lance check pin 15 is urged left while compressing the compression spring 16, an excessive pressure will not be exerted on the lance 34, and damage to the lance 34 is thereby prevented. In the above examination, there are occasions when the distal end portion 15a of the lance check pin 15 to be inserted into the lance flexing space 32a in the connector 30 is deformed or bent upwardly, or is obliquely and/or upwardly inserted into the lance flexing space 32a. Even in such a case, upon insertion of the lance check pin 15 into the lance flexing space 32a, the upper surfaces of the guide portions 15b contact the upper inner surface of the lance flexing space 32a over a predetermined length in the direction of the length of the lance check pin 15. In addition the lower surface of the lance check pin 15 contacts the lower inner surface of the lance flexing space 32a. Therefore, the lance check pin 15 is corrected into a proper posture, and can be inserted into the lance flexing space 32a while being guided by guide portions 15b to this posture. As described above according to the invention, when the metal terminal 33 is disposed in the proper position, the distal end portion 15a of the lance check pin 15 can be positively brought into the position beneath the lance 34. Therefore, to misjudge that the metal terminal 33 is disposed in an incompletely-inserted position, although the metal terminal is actually disposed in the proper position, is prevented, and the highly-reliable examination can be carried out. In addition, the relief recess 15c is provided at the distal end portion 15a of the lance check pin 15, and when the distal end portion 15a of the lance check pin 15 is brought into underlying relation to the lance 34, the guide portions 15b of the lance check pin 15 will not interfere with the stabilizers 33a of the metal terminal 33, thereby preventing a situation in which the advance of the lance check pin 15 is prevented by the interference of the guide portions 15b with the stabilizers 33a. The electrical contact members 17 can be connected to the conduction examination circuit for the wire harness, and by performing one operation, that is, the setting of the connector 30 in the inspection housing 11, the position of the lance 34 (that is, whether each metal terminal 33 is disposed in the proper position) and whether each metal terminal 33 is mounted in the predetermined cavity 32 can be confirmed at the same time, and the examination operation is made reliable and efficient. Furthermore, the sliders 14 are mounted respectively in the cavities 12 in the inspection housing 11, and the lance check pin 15 and the electrical contact member 17 are integrally provided on each slider to provide a single unit. Therefore, it is only necessary to provide units corresponding in number to the number of poles of the connector 30 to be examined. The integral check pin and electrical contact member 17 can be adapted for inspection of any type of connector. In the event of a malfunction, it is only necessary to exchange such a defective unit, and therefore the maintainability is excellent. Fig. 6 shows a second embodiment of the terminal inspecting apparatus and method aspects of the present invention. The basic difference from the above embodiment is that this embodiment is of such a construction that an inspection housing 11 is mechanically moved toward a connector 30. Other elements are similar to those of the first embodiment and, therefore, to avoid repeated explanation, identical portions are denoted by the same reference numerals, respectively, and only different portions will be described in detail. The inspection housing 11 is mounted on a base plate 41 for movement to the right and left in Fig. 6, and is moved by pivotally rotating a cam handle 42 about a shaft 42a mounted on the base plate 41. Lance check pins 15 and electrical contact members 17 used in this embodiment are the same as those in the preceding embodiment. A connector holder 43 is fixedly mounted on a left end portion (Fig. 6) of the base plate 41. The connector holder 43 comprises a U-shaped support block 44, a U-shaped back plate 45 releasably mounted on the support block 44, and an upwardly-open connector fixing groove 46 is provided between the support block and the back plate. Elongate protuberances (not shown) formed on an outer surface of the connector housing 31 are fitted in the connector fixing groove 46 from the upper side, and the two elongate protuberances are vertically guided by it, so that the connector housing 31 received by the support block 44 is retained in position. In this condition, the connector housing 31 is immovable in right and left directions. The connector 30, manually or by machine, is fitted or set in the connector holder 43 from the upper side. When the cam handle 42 is pivotally moved in a direction of an arrow 70 to move the inspection housing 11 to the right in Fig. 6, each of the lance check pins 15 and the associated electrical contact members 17 are moved toward the connector 30, and the distal end portion of the lance check pin 15 is inserted into a lance flexing space 32a beneath a lance 34. The electrical contact member 17 is moved toward an associated metal terminal 33, as described above for the preceding embodiment. As a result, the condition of attachment of each metal terminal 33, as well as the connection of the metal terminal 33, is checked. According to the invention, in this embodiment, also, guide portions 15b for keeping the lance check pin 15 in a proper position in the lance flexing space 32a are formed at a distal end portion 15a of the lance check pin 15. Therefore, when the metal terminal 33 is disposed in a proper position, the distal end portion 15a of the lance check pin 15 can be positively brought into a position beneath the lance 34. This eliminates the possibility that it is judged that the metal terminal is disposed in an incompletely-inserted position when the metal terminal 33 is disposed in the proper position, and therefore highly reliable examination can be carried out. In Fig. 6, the inspection housing 11 is moved by pivotally moving the cam handle 42; however, in contrast with this, the checker housing 11 may be fixed while the connector holder 43 holding the connector 30 may be moved, or the two may be moved toward each other. In addition, the judgment means for judging from the position of the lance check pin 15 may be achieved using devices other than the electrical contact member 17 that is mounted for movement with the lance check pin 15.

Claims: A connector examination device (10) for examining a connector (30) having metal terminals (33) inserted into cavities (32) formed in a connector housing (31), and lances (34) formed in the connector housing (31) that are elastically deformed into lance flexing spaces (32a) upon insertion of the metal terminals (33), said lances (34) being restored to engage said metal terminals (33) when said metal terminals (33) are brought into a properly-attached condition, to retain said metal terminals (33) against withdrawal, said device (10) comprising: an inspection housing (11) having a setting portion for receiving the connector (30) to be examined; lance check pins (15) insertable into said lance flexing spaces (32a), said lance check pins (15), upon insertion, abutting against the lances (34) when the metal terminals (33) are in an improperly-attached condition, sliders (14) mounted on said inspection housing (11) for movement toward and away from the connector (30); and a judgment means (17, 18) which is mounted on each of said sliders (14), wherein each of said judgment means (17, 18) comprises an electrical contact member (17) being connected to a conduction examination circuit for a wire harness; wherein each of said lance check pins (15) has at least one guide portion (15b) for contacting an inner surface of each of said lance flexing spaces (32a) so as to keep said lance check pins (15) in a proper orientation in said lance flexing spaces (32a); said electrical contact members (17) are mounted for movement with the lance check pins (15) so as to engage the metal terminal (33) received and retained in the properly-attached conditions in the connector housing (31) against withdrawal, and in that said judgment means (17, 18) are for judging from a position of the lance check pins (15) whether the lance check pins (15) are abutted against the lances (34). A connector examination device according to claim 1, wherein said lance check pin (15) has a relief recess (15c) for preventing said at least one guide portion (15b) from interfering with stabilizers (33a) extending from the metal terminal (33) on opposite sides of said lance (34). A connector examination device according to claim 1 or 2, said device further comprising: a connector holder (43) for holding the connector (30) to be examined, wherein the inspection housing (11) is provided in opposed relation to said connector holder (43); and a drive mechanism for moving at least one of said connector holder (43) and said inspection housing (11) toward the other. A device (10) for inspecting a terminal (33) inserted within a connector housing (31), said connector housing (31) having a lance (34) capable of securing the terminal (33) in a locking position and a lance flexing space (32a) into which the lance (34) flexibly extends as the terminal (33) is inserted within the connector housing (31), said device comprising: a lance check pin (15) that is inserted in the lance flexing space (32a); wherein a means (l5b) is provided on the lance check pin (15) for guiding the tip portion (15a) of the lance check pin (15) to a first position below the lance (34) when the lance (34) is disposed in the locking position, even when the lance (34) partially protrudes within the lance flexing space (32a) and the tip portion (15a) is at least one of irregularly formed and obliquely inserted. The device of claim 4, wherein said lance check pin (15) is operatively connected to an electrical contact member (17) that contacts said terminal (33) when the terminal (33) is in the locking position, and does not contact the terminal (33) when the terminal (33) is in an unlocked position wherein the tip portion (15a) of the lance check pin (15) engages an end portion of the lance (34) disposed in the lance flexing space (32a). The device of claim 5, wherein the lance check pin (15) and the electrical contact member (17) are connected to a slider (14) to form an inspection unit provided within an examination device. The device of claim 6, wherein the inspection unit slides within said inspection device against the bias of a spring (16) when the tip portion (15a) of the lance check pin (15) engages said end portion of said lance (34) and the terminal (33) is in the unlocked position, whereby the electrical contact portion does not contact the terminal (33). The device of claim 7, wherein the electrical contact member (17) is connected to a circuit for signaling the locking position and the unlocked position. The device of claim 4, further comprising a first support (43) provided for the connector housing (31) and a second support (11) provided for the lance check pin (15), wherein the first and second supports are moved into engagement with each other to inspect the position of the terminal (33). The device of claim 9, wherein one of the first and second supports is provided with a crank (42) that reciprocates the connector housing (31) back and forth with respect to the lance check pin (15). The device of claim 4, wherein the means for guiding includes at least one guide portion (15b) provided near the tip portion (15a) of the lance check pin (15). The device of claim 4, wherein the guiding means comprises two guide portions (15b, 15c) that straddle the lance (34) and define a recess that provides a space in which stabilizers (33a) formed on the terminals (33) can be disposed. A method for inspecting a terminal (33) inserted within a connector housing (31), the connector housing (31) having a lance (34) capable of securing the terminal (33) in a locking position and a lance flexing space (32a) into which the lance (34) flexibly extends as the terminal (33) is inserted within the connector housing (31), the method comprising: inserting a lance check pin (15) into the lance flexing space (32a); characterized by the step: guiding a tip portion (15a) of the lance check pin (15) to a first position below the lance (34) when the lance (34) is disposed in the locking position, even when the lance (34) partially protrudes within the lance flexing space (32a) and the tip portion (15a) is at least one of irregularly formed and obliguely inserted. The method of claim 13, wherein the tip portion (15a) includes at least one guide portion (15b) that ensures said tip portion (15a) is guidable to said first position when the lance (34) is in the locking position. The method of claim 14, wherein the at least one guide portion includes two spaced guide portions, the method including straddling the lance (34) with the spaced guide portions when the lance check pin (15) is in the first position. The method of claim 15, wherein the tip portion (15a) further includes a relief recess (15c) disposed between the two spaced guide portions and further toward a distal end of the tip portion (15a) than the two guide portions, the relief portion providing a space between the terminal (33) and the tip portion (15a) in which stabilizers (33a) formed on the terminals (33) are disposed. The method of claim 13, further comprising indicating one of said locking position and an unlocked position, said unlocked position being indicated when said tip portion (15a) of said lance check pin (15) engages an end portion of said lance (34) disposed within the lance flexing space (32a). The method of claim 17, wherein said indicating includes operatively connecting said lance check pin (15) to an electrical contact member (17) that contacts said terminal (33) when the terminal (33) is in the locking position, and does not contact the terminal (33) when the terminal (33) is in the unlocked position. The method of claim 18, wherein the indicating includes connecting the lance check pin (15) and the electrical contact member (17) to a slider (14), thus forming an inspection unit provided within an examination device. The method of claim 19, wherein the indicating includes sliding the inspection unit within said examination device against the bias of a spring (16) during the inserting when the tip portion (15a) of the lance check pin (15) engages said end portion of said lance (34) and the terminal (33) is in the unlocked position, whereby the electrical contact portion does not contact the terminal (33). The method of claim 18, wherein the indicating includes connecting the electrical contact member (17) to a circuit for signaling the locking position and the unlocked position. The method of claim 13, further comprising providing the connector housing (31) on a first support (43), providing the lance check pin (15) on a second support (11), and moving the first and second supports toward each other to inspect the position of the terminal (33). The method of claim 22, further comprising providing one of the first and second supports with a crank (42), and using the crank (42) to reciprocate the connector housing (31) back and forth with respect to the lance check pin (15).

Inventors: AOYAMA MASAHIKO, ATSUMI KEIGO, SAIJO EIJI, AOYAMA, MASAHIKO, ATSUMI, KEIGO, SAIJO, EIJI, AOYAMA, MASAHIKO, C/O SUMITOMO WIRING SYSTEMS, LTD, ATSUMI, KEIGO, C/O SUMITOMO WIRING SYSTEMS, LTD., SAIJO, EIJI, C/O SUMITOMO WIRING SYSTEMS, LTD.
Applicants: SUMITOMO WIRING SYSTEMS, SUMITOMO WIRING SYSTEMS, LTD.
Application year: 1994
Main classification: H01R13
IPC codes: H01R43, H01R13